Fan blade connector component with skeleton and method of manufacturing such

ABSTRACT

A fan blade connector component having a moldable ornamental housing that encloses a skeleton which includes links which span between adjacent posts having a threaded bore therein. The links include opposing side walls, a top wall, and a land therebetween. A plurality of spaced-apart openings extend through the top wall for securing the skeleton within the moldable ornamental housing.

TECHNICAL FIELD

The present invention relates to connectors components for attaching fan blades to fan motors. More particularly, the present invention relates to the interior structures for embedding in fan blade connectors components and a method of manufacturing such.

BACKGROUND OF THE INVENTION

Electrically powered ceiling fans typically have a motor mounted within a stationary housing that is suspended from a ceiling. In operation, the motor rotates an annular array of connectors coupled to blades. The blade connectors of ceiling fans are typically mounted to the blade through a series of mounting bolts or screws that pass through holes in the fan blade and thread within threaded mounting holes in the blade connector. Alternatively, the blade connector includes a medallion which is positioned against the blade opposite the blade mounting portion of the blade connector, thereby sandwiching the blade therebetween.

Blade connectors are typically made of die cast metal. These materials allow for limited aesthetic flexibility and provide the rigidity and support needed to support a fan blade that is spinning upwards of 200 rpm. The use of these materials however is costly due to the tooling process needed to manufacture the blade connector and because of the costs of the raw material.

Accordingly, there is a need in the art for an improved blade connector component, such as a blade connector or blade connector medallion, that readily provides aesthetic flexibility yet is strong enough to support the fan blades of fans. It is to such that the present invention is directed.

SUMMARY OF THE INVENTION

A skeleton for a cast fan blade connector component comprises at least two posts having a threaded bore for receiving a fastener, and a link that interconnects adjacent posts.

A method of manufacturing a fan blade connector component comprises the steps of providing a skeleton having at least two posts having a threaded bore for receiving a fastener and a link spanning the posts, and forming an ornamental housing about the skeleton so as to encase the link and at least a portion of the posts yet allowing the bore of each post to remain exposed from the housing.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates in perspective partially cut-away view a skeleton for a fan blade connector component embodying principles of the invention in a preferred form.

FIG. 2 illustrates in perspective view of a skeleton for a fan blade connector component in another preferred form of the invention.

FIG. 3 illustrates a perspective view of a skeleton shown partially encased within a blade connector medallion.

FIG. 4 illustrates in perspective exploded view the skeleton shown partially encased in a fan blade connector for attaching a fan blade to a fan motor.

DETAILED DESCRIPTION

With reference to the drawings in which like parts have like reference numerals, FIG. 1 illustrates in perspective partially cut-away view of a skeleton 10 for a fan blade connector component 12, which may be utilized to form a blade connector or a blade connector medallion. The skeleton shown in FIG. 1 is preferably designed to be utilized specifically with a blade connector medallion. The skeleton 10 includes a hub 14 from which a plurality of elongated links 16 extend radially. In the illustrated embodiment, the skeleton 10 is made of a cast metal, such as zinc, but may also be made of a stamped sheet metal or other similarly formed metal. The skeleton 10 may be made of any substantially rigid material capable of supporting a fan blade and withstanding the force exerted upon the blade connector during the revolution of the fan blade. The skeleton 10 is of sufficient overall dimension to support fan blades of varying length and weight.

The links 16 may be spaced-apart equidistantly or may be oriented at varying angles. In the illustrated embodiment the skeleton has three links wherein two pairs of the links 16 are approximately 130 degrees apart as indicated at 18 and one pair is approximately 100 degrees apart as indicated at 20. It is understood, however, that there may be varying numbers of links at various lengths. Each link 16 terminates at a post 22 having a threaded bore 24 therein and a closed bottom 26.

Each links 16 has opposing side walls 28 and a land 30 spanning therebetween. The land 30 and the side walls 28 cooperatively define a first valley 32 and an opposing second valley 34. A top wall 35 extends between the tops of the side walls 28. The top wall 35 has a plurality of spaced apart openings 36 extending therethrough. In the present embodiment, the openings 36 on each link 16 provide cavities or spaces through which resin, upon hardening during fabrication, may embed. This, in turn, helps secure the skeleton 10 within the blade connector 12.

FIG. 2 illustrates in perspective exploded view the skeleton 10 shown encased in a fan blade connector component in the form of a blade connector medallion. The fan blade connector medallion includes an exterior ornamental shape or housing 37. FIG. 4 illustrates in perspective view of the skeleton 10 shown encased in a fan blade connector 41. It should be understood that the skeleton may be used with a fan blade connector or a fan blade connector medallion as shown in U.S. Pat. No. 5,304,037, which is specifically incorporated herein. The blade connector is coupled to a fan motor 42 through additional links which extend to the motor, shown in phantom lines. In the illustrated embodiment, the blade connector 12 has a motor mounting flange or portion 44 and a blade mounting portion 46. The motor mounting flange 44 connects the blade connector 12 to the motor 42 by unshown mounting bolts. The blade mounting portion 46 encases the skeleton 10 and secures the blade connector 12 to the fan blade 40.

During fabrication, the cast metal skeleton 10 is placed in a mold and over-molded with a resin or other suitable moldable material in a desired ornamental shape. This may be done to form the blade mounting portion 46 of the blade connector 41, as shown in FIG. 4, or to form the blade connector medallion, as shown in FIG. 3. It is understood, however, that the skeleton may be encased in any polymerized synthetic or chemically modified natural resin including thermoplastic materials such as polyvinyl, polystyrene, and polyethylene or thermosetting materials such as polyesters, epoxies, and silicones. Resin has the advantage of providing aesthetic flexibility and cost efficiency in comparison to metals such as zinc or brass or other metal alloy.

Each blade connector medallion or blade connector attaches one ceiling fan blade 40 to the motor. Each ceiling fan blade 40 has a plurality of mounting holes 43 that correspond to the posts 22 on the skeleton 10. In the illustrated embodiment, three mounting holes 43 are aligned with the three posts 22 of the skeleton 10. A mounting screw 48 inserts through a respective one of the mounting holes 43 and into the threaded bore 24 of each post 22 to secure the blade connector medallion to a blade connector. Each post of the skeleton 10 has a short enough height to allow the skeleton 10 to be completely molded with resin with the exception of the post ends, yet sufficient height to allow mounting screws 48 to engage the threaded bore 24 of each post 22.

FIG. 3 illustrates in perspective view an alternate embodiment of the skeleton 10 a for the fan blade connector medallion 12. The skeleton 10 a includes at least two posts 22 each having the threaded bore 24 for receiving a fastener such as a screw. Each of the posts 22 includes the closed bottom 26.

In the illustrated embodiment, the links 16 form a triangular-like structure. The skeleton 10 a includes three posts 22 interconnected by three links 16. The link 16 interconnects adjacent posts 22. The skeleton 10 a includes two links 16 of a first length and a third link of a second length less than the first length. The links 16 may have varying lengths in comparison to each other and may include varying numbers of links 16 and posts 22 so as to form a variety of polygon-type structures. Each link 16 includes openings 36 therein.

The skeleton 10 a illustrated in FIG. 3 is similarly encased in the moldable fan blade connector or blade connector medallion 12 for attaching the fan blade 40. During fabrication, the metal cast skeleton 10 a is over molded with a resin and encased therein. It is understood, however, that the skeleton may be encased in any polymerized synthetic or chemically modified natural resin including thermoplastic materials such as polyvinyl, polystyrene, and polyethylene or thermosetting materials such as polyesters, epoxies, and silicones.

Each blade connector or medallion 12 attaches to one of the ceiling fan blades 40. The mounting holes 43 in the fan blade 40 align with the posts 22 of skeleton 10 a. The mounting screws 48 insert through the respective mounting holes 43 and into the threaded bores 24 of the posts 22. Each post of the skeleton 10 has a short enough height to allow the skeleton 10 a to be completely molded with resin and encased within the fan blade connector 12, yet sufficient height to allow mounting screws 48 to engage the threaded bore 24 of each post 22.

It thus is seen that a skeleton and the encompassing blade connector or medallion is now provided which is not only cost efficient but esthetically alterable thus overcoming the shortcomings of the existing art. It should be understood that many modifications, additions and deletions, in addition to those expressly recited, may be made thereto without departure from the spirit and scope of the invention as set forth in the following claims. 

1. A skeleton for a cast fan blade connector component, comprising: at least two posts having a threaded bore for receiving a fastener; a link that interconnects adjacent said posts.
 2. The skeleton as recited in claim 1, wherein said skeleton includes three said posts interconnected by three said links.
 3. The skeleton as recited in claim 2, wherein two said links are of a first length and the third said links is of a second length less than said first length.
 4. The skeleton as recited in claim 1, wherein said link includes a plurality of openings therein.
 5. The skeleton as recited in claim 1, made of a cast metal.
 6. The skeleton as recited in claim 1, wherein said link includes a hub.
 7. A skeleton for a cast fan blade iron component, comprising: a hub; a plurality of elongated links extending radially from the hub; and a plurality of posts, each post being positioned at a distal end of a said link and having a threaded bore therein.
 8. The skeleton of claim 7, wherein said links include a plurality of spaced-apart openings therein.
 9. A cast fan blade connector component for attaching a fan blade to a fan motor, comprising: a skeleton having a plurality of elongated links and a plurality of posts interconnected to each other through said links, said posts having a threaded bore therein; and an ornamental body mounted at least partially about said skeleton with said post bores exposed outside said ornamental body.
 10. The fan blade connector component as recited in claim 9, wherein said skeleton is made of a cast metal.
 11. The fan blade connector component as recited in claim 9, wherein the ornamental body is made of a resin.
 12. The fan blade connector component of claim 9, wherein said fan blade connector component is a fan blade connector.
 13. The fan blade connector component of claim 9, wherein said fan blade connector component is a fan blade connector medallion.
 14. A method of manufacturing a fan blade connector component, comprising the steps of: (a) providing a skeleton having at least two posts having a threaded bore for receiving a fastener and a link spanning the posts, and (b) forming an ornamental housing about the skeleton so as to encase the link and at least a portion of the posts yet allowing the bore of each post to remain exposed from the housing.
 15. The method as recited in claim 14, wherein the skeleton has three posts interconnected by three links.
 16. The method as recited in claim 14, wherein two of the links are of a first length and a third one of the links is of a second length less than the first length.
 17. The method as recited in claim 14, the skeleton made of a cast metal. 